Success Story Collection

LNG Supply Chain

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Bulletin 00A01A54-01EN
 ■Contents

01│ South Hook LNG Terminal Ltd.

03│ MISC Berhad

05│ Korea Gas Corporation

07│ Oman Liquefied Natural Gas LLC

Success Story Collection 09│ Terminale GNL Adriatico Srl
LNG Supply Chain
11│ PT Badak

13│ Saibu Gas Co., Ltd.

This is a showcase of success stories from our customers worldwide.
17│ Shanghai LNG Company Limited
Many leading companies are using
19│ Skangass AS
Yokogawa products to manage their plants and processes.
21│ PTT LNG Company Limited

23│ Hazira LNG Private Limited


LNG Supply Chain
Plant Information
Location: South Hook, Milford Haven, UK
Order date: March 2005
Completion: April 2010
South Hook LNG Terminal Ltd.
Yokogawa Provides CENTUM CS 3000 and ProSafe-RS
for the Largest LNG Terminal in Europe
Executive Summary
The demand for natural gas is growing rapidly and at the same
time indigenous gas production in European Union is going
down. Experts predict that the resulting import requirements in
the European Union in 2030 will be between 1.5 and 2 times the
import amount of 2007. One of the options to close the resulting
supply gap is through LNG imports. As a consequence, liquefied
natural gas (LNG) facilities are under pressure to deliver not just
now, but well into the future. Consequently, a requirement for
LNG terminals is that they have exceptionally reliable field proven
process automation solutions that will be supported for at least 15
years, and which in practical terms can be expected to be longer.
The South Hook Terminal provides the UK with a significant
proportion of its natural gas requirements. It is an integral part of
the Qatargas 2 integrated value chain and is the largest Liquefied
Natural Gas re-gasification terminal in Europe.
The South Hook LNG terminal and jetty
1 Success Story Collection
The South Hook re-gasification Terminal is the stage in the LNG
process which changes it back from the liquid to gaseous state.
This is then delivered to the UK’s homes and businesses via the
UK’s national grid network.
The LNG is delivered to South Hook by a state of the art fleet of
double-hulled ships which brings the LNG from Qatar’s immense
North Field, to the safe, deep water in Milford Haven.
The South Hook Terminal also plays a major role in the
strengthening of the strategic partnership between the state of
Qatar and UK. LNG imports greatly increase the UK’s security and
diversity of gas supply while helping to ensure that natural gas
remains a competitive source of energy.
The Challenges and the Solutions
Yokogawa Europe successfully completed the implementation of
the full ICSS automation control system project which includes
flagship products of distributed control system (DCS) CENTUM
CS 3000, Yokogawa’s safety instrumented system ProSafe-RS
and Exaquantum - Yokogawa’s Plant Information Management
System (PIMS). For design and training purposes the Yokogawa
scope also included an Operator Training System (OTS) based on
the Visual Modeler dynamic simulation software.
The South Hook Terminal facility comprises a ship unloading
system, five dual containment 155,000 m3 LNG storage tanks, and
duplicated re-gasification and gas send-out systems.
Plant Safety Operation
Owners of LNG terminals are subject to compliance with many
laws, regulations, standards and guidelines which need to
be met to ensure that the health and safety and commercial
viability of all of its stakeholders are not compromised.
These comprehensive requirements influence the design,
construction, operation, and maintenance of an LNG facility.
Yokogawa’s skills, expertise and experience is not just limited
to its product but recognises the importance of understanding
the LNG process. In order to be able to implement a successful
fully automated solution, Yokogawa utilises its experience and
specific knowledge of LNG terminal control system automation.
Yokogawa safety consultants are involved at the earliest stages
of development and can participate, for example, in HAZOP
studies and SIL studies. Yokogawa supported, designed and
supplied a full automation control system for this terminal,
which incorporated the DCS (distributed control system),
emergency shutdown (ESD) system, fire and gas (F&G) system,
fire and gas devices, asset management system, data historian
system and operator training simulator. The basis of this LNG
terminal solution is Yokogawa’s CENTUM CS 3000 R3 DCS
system and ProSafe-RS safety instrumented system, which are
considered the most reliable process automation system on the
market.
As LNG EPC projects have increased in size and complexity,
owners have increasingly employed Yokogawa during front
end engineering design (FEED) activities, utilising Yokogawa’s
extensive experience in LNG supply chain automation.
Central control room
Data Management by Exaquantum
CENTUM CS 3000 and ProSafe-RS were totally integrated
with 17 sub-vendor systems and all process operation data
needing to be visualised for efficient terminal operation.
The plant management team operates daily KPI reporting
that the terminal utilises to monitor and continually improve
its efficiency. Yokogawa’s Exaquantum plant information
management system (PIMS) is the tool that South Hook utilise
to manage this important part of their operation. To ensure
operators can see their process information clearly, various
process information in real time data are always displayed on
their large operator screen. This enables the process situation to
be known in advance and ensures that the operator can always
take any necessary proactive action. Finally, gas nomination and
allocation is smoothly executed by having Exaquantum provide
the required data to the Terminal Access System that handles .
South Hook LNG Terminal Ltd. / UK
State-of-the-art Training Facilitation
In managing and operating LNG terminals effectively, terminal
owners are frequently faced with the need to train and
refresher train staff in order to maintain competitiveness and
maximise efficiency, process and safety knowledge. It can be
difficult for LNG owners to find experienced operators, and
therefore need to train their own. An experienced operator may
only require training on the specific system and not always on
the plants process. However, inexperienced operators may also
need to be trained in process behaviours and specific operator
scenarios. In the South Hook LNG terminal’s case, Yokogawa’s
OmegaLand plant operator training simulator (OTS) helps to
reduce costs, optimize LNG terminal processes, and improve
reliability by training operator staff in trouble-free start-up and
load operation, prior to real plant operation. By establishing a
network connection between OmegaLand and an actual DCS
(the CENTUM CS 3000), it is possible for operators to receive
realistic training in a virtual environment.
Training is available for procedures such as plant startup and
load change, abnormal conditions such as an instrument or
equipment failure, and exceptional emergency situations
such as earthquakes, fires and runaway reactions. Because
the simulator uses exactly the same algorithms as the actual
control system, individuals can be fully trained to respond to
emergencies, however rare, that could lead to a plant shutdown.
The dynamic model not only facilitates the training of operators,
but also allows the designers to check the dynamic aspects of
the design. Having such a dynamic simulation environment
attached to the actual control and safety systems, additionally
supports the validation of process operating procedures.
Operator training simulator
Customer Satisfaction
According to Maurice Khoury the SHLNG Facilities, Control &
Instrumentation Lead Engineer, “ We are very happy using
Yokogawa’s DCS and SIS, as well as their software packages.
The South Hook LNG Terminal can provide up to 20% of UK gas
demand, so the plant runs 24 hours a day, 7 days a week, 365
days a year. Yokogawa’s highly reliable systems and products are
contributing to this continuous operation.” He added, “Yokogawa
are a significant partner here and we will continue to work as one
seamless team throughout the plant’s asset lifecycle.”
Success Story Collection 2
 MISC Berhad / Malaysia
LNG Supply Chain

Plant Information
Location: Malaysia

Tenaga Class: 5 Ships

Capacity: 130,000 cbm per ship
Start: 2002

MISC Berhad Finish: 2006

Integrated Automation System (IAS) for MISC LNG

Carrier Tenaga and Seri ‘A’ Class Seri ‘A’ Class: 5 ships
Capacity: 145,000 cbm per ship
Start: 2005
Finish: 2007

Project Profile
Yokogawa has been selected to supply the CS3000 for Integrated
Automation System (IAS) and Boiler Integration as well selected
field instruments for MISC Tenaga and Seri ‘A’ Class of LNG
Carriers.
One of the tasks in the Tenaga Class project is to replace the
existing panel instrumentation and obsolete PLCs with the
advanced CS 3000 IAS which partly will extend the service life of
the ships built in the early 1980’s. Whereas in the Seri ‘A’ Class, the
CS 3000 IAS will provide a reliable automation system onboard of
all the newly build ships each with capacity of 145,000 cbm. The
certification bodies for the Tenaga and Seri ‘A’ class are from ABS
and BV respectively.
The Challenges and the Solutions
There was a requirement for an intensive site survey onboard
of the Tenaga ships to ensure that the engineering and design
works could be carried out successfully. A dedicated survey team
comprises of Yokogawa global team with the assistance from the
end-user did the onboard survey to map out all the necessary
engineering details.
Part of the scope of work is to convert the existing panel
instrumentation made in the early 1980’s to accommodate the
latest in the DCS technology. These include the previous boiler
control which was based on obsolete PLC to be integrated into
the new DCS. With the Yokogawa capability in handling major
project using the Main Automation Contractor (MAC) approach as
well as with existing close cooperation from Marine Boiler Maker
and Marine Consultant, the project was able to be successfully
completed even with a really tight yard schedule, all within a
period of 2 months per ship on the average.
In the Seri ‘A’ Class ships, the challenge was in different nature
as these are newly build. With the knowledge gained and the
same dedicated team all the engineering, installation, testing and
commissioning as well as during sea trial, the Seri ‘A’ projects have
been successfully delivered to the satisfaction of customers. This
including the DCS integration of with Terasaki Power Management
System as well as integration of ship’s boiler system.
Benefits Realized
With the completion of the retrofitting of the new CS 3000 IAS in
Tenaga and new installation on  Seri ‘A’ Class LNG Carriers, MISC
could be ensured of better information visibility, performance
foresight, and operational agility to deliver overall operations
excellence, reliability, safety and on-time cargo deliveries to the
confidence of their charterers.
MISC operation team could also benefit from the global Yokogawa
support around the world in all the destinations during the
Tenaga and Seri ‘A’ Class voyage.
To ensure the adherence to the highest safety standards, for all
periodic vessels’ inspection and audit conducted at the Malaysian
dry docks, MISC will be guaranteed of Yokogawa support and
expertise from the Malaysian office. Because of similar operating
system the Tenaga and Seri ‘A’ Class ships’ crew could be
interchangeable and hence optimise the cross-fleet integration
and operations.
MISC will also benefit from the training and process simulation at
Yokogawa DCS Training Simulator Centre located at their world
class Malaysian Maritime Academy to train sea personnel.
Customer Satisfaction
One of the MISC engineer commented, “We want an idiot proof,
user friendly and reliable IAS system to ensure safe operations for
our LNG carriers. Yokogawa CS 3000 system has proven in both
the Tenaga and the Seri Class LNG carriers that their hardware
is very reliable with very less problem. This means that we have
fewer spare parts to purchase and hence a reduced maintenance
cost and a faster turn-around for the vessels.”
He further added, “Yokogawa CS 3000 software and operating
system proven to be most user friendly as almost any ship
engineer can familiarise with the system in a very short time. The
system is also very easy for our trouble shooting works.”
Customer Profile
MISC Berhad (MISC), a subsidiary of the PETRONAS Group
of Companies, is a renowned leading international shipping
and logistics company with a formidable presence in energy
transportation and marine engineering. With a fleet of 27 LNG
tankers, which is expected to expand to 29 by April 2009, MISC is
the world's single largest owner operator of LNG Carriers.

System Details
System: CENTUM CS 3000

3 Success Story Collection Success Story Collection 4


LNG Supply Chain
Plant Information
Location: Incheon, South Korea
First Installation: 1998
Current Migration: 2011 (plant 1)
Korea Gas Corporation
World’s Largest LNG Terminal Relies on CENTUM to
Maximize Safety and Reliability
Executive Summary
Established by the Korean government in 1983, Korea Gas
Corporation (KOGAS) is the world’s largest importer of LNG, and
the country’s sole importer of this important resource. KOGAS is
fully committed to providing clean, safe, and convenient energy
to the people of Korea. The company currently operates LNG
receiving terminals in Incheon, Pyeongtaek, and Tongyeong,
and distributes natural gas and gas by-products via a 2,739 km
pipeline network to power plants, gas utility companies, and city
gas companies throughout the country.
The Incheon LNG terminal is the world’s largest LNG receiving
complex, and it supplies natural gas to the Incheon and Seoul
metropolitan areas, which account for 40% of the country’s natural
gas demand. Built on a 990,000 m2 plot of reclaimed land 8.7 km
off the coast, the terminal has two plants with a jetty capable of
accommodating two ultra-large LNG carriers of up to 100,000
tons in size and a total of ten 100,000 m3 above-ground storage
tanks, two 140,000 m3 underground tanks, and eight 200,000 m3
underground tanks, giving it a total storage capacity of 2,880,000
m3 (Kl). The total gas send out capacity of the Incheon terminal is
4,350 tons per hour.
In 1996, Yokogawa Korea installed a CENTUM CS production
control system at plant 1 of the Incheon terminal, and migrated
this system to CENTUM VP in 2011. With the construction by
KOGAS of plant 2 in 2004, Yokogawa Korea installed a CENTUM
CS system, and subsequently installed another CENTUM CS 3000
system in 2009. Engineering work is now underway at plant
2 for migration to CENTUM VP. The Incheon terminal utilizes
Yokogawa’s CENTUM systems for the control and monitoring
of facilities throughout both plants, including unloading arms,
storage tanks, recondensors, open rack vaporizers (ORV),
submerged combustion vaporizers (SMV), and trunk lines with
metering stations.
5 Success Story Collection
The Challenges and the Solutions
Safe operation
At LNG receiving terminals, safety is a paramount concern
with the transfer and storage of LNG from carriers. It is very
important to maintain a constant pressure inside the storage
tanks, which requires careful control of the operation of boil-off
gas (BOG) compressors, recondensors, and pumps. By means
of sequence functions, CENTUM operators can easily control
the process from a remote location, starting and stopping
the BOG compressors depending on BOG temperature, gas
composition, and volume. In addition, KOGAS has a disaster
protection system for dealing with critical situations, and
personnel in the central control room can share information in
real time with operators in plants 1 and 2, ensuring a timely and
well coordinated response if fire or a gas leak is detected.
Steady gas supply
It is very important for KOGAS to be able to adjust flexibly to
shifts in demand in the gas that it supplies to power plants,
industrial companies, and residences. While seawater in an
ORV is normally used to cool and vaporize the LNG, in periods
of peak demand operation can be automatically switched over
to an SMV that relies on the combustion of BOG to vaporize the
LNG. Every aspect of these vaporization processes, from the
switching on and off of pumps to the control of vaporization
temperature and gas pressure, is carefully configured in the
CENTUM system. The adjustment to shifts in demand is fully
automated at this terminal, ensuring uninterrupted supply.
Korea Gas Corporation / South Korea
KOGAS Incheon LNG terminal
Customer Satisfaction
Proactive maintenance for asset excellence People at the KOGAS Incheon LNG terminal, says, “With CENTUM
Systems from other vendors that control the plant’s offloading, and other systems, we have built an enterprise-wide operating
tank gauging, pipe line monitoring, metering, and other information system. The visualization of all process data allows
processes are all integrated via a Modbus interface with each us to maintain a clear picture of the execution of our business
plant’s CENTUM production control system. The data from plans, create optimal LNG supply chain scenarios, and make quick
these processes is used to make production reports, calculate decisions and timely adjustments. With the CENTUM system,
plant efficiency, and analyze performance. For example, operability and safety are enhanced, and operators as well as
operators use an accumulated running time report to track managers can maximize the effectiveness of their activities.” They
how long each LNG pump, air compressor, and other rotating went on to say, “We appreciate the continual support and the
equipment throughout the terminal has been operating. This solutions that Yokogawa Korea has provided us. Yokogawa is one
enables a proactive approach to the scheduling of inspections of our best partners.”
to determine when repair or replacement will be necessary.
This puts the right information at the right time into the
hands of the right operators and managers, so they can make
timely and correct decisions. The system can also generate the
following types of reports used by plant specialists to analyze
overall performance of the LNG terminal as well as individual
processes:
1. LNG cost analysis
2. Electric power consumption
3. Fuel gas consumption
4. Unit operation cost
5. Daily cost analysis
6. LNG unloading
7. BOG treatment
8. Odorant treatment
9. Running time accumulation
10. Yield accounting
CENTUM VP operator in central control room
Success Story Collection 6

LNG Supply Chain
Plant Information
Location: Qalhat, Sultanate of Oman
Order date: September 2012
Completion: December 2013
Oman Liquefied Natural Gas LLC
Upgrade of PCS Brings Higher Operation Efficiency
and Productivity at Gas Liquefaction Plant in Oman
Executive Summary
Oman Liquefied Natural Gas LLC (OLNG) is a limited liability
incorporated joint venture company established by a Royal
Decree and operated under the laws of the Sultanate of Oman. It
engages in the business of producing and selling liquefied natural
gas (LNG) and byproduct natural gas liquids (NGLs).
The Company undertakes, directly or indirectly, project operations
and activities necessary to liquefy, store, transport and market
Oman’s natural gas and to deliver LNG to customers in the global
markets. The Company operates three liquefaction trains at its
site in Qalhat near Sur with a capacity of 10.4 million tonnes per
annum.
The produced gas at the Barik, Saih Nihayda and Saih Rawl gas
fields are gathered at the Saih Rawl Plant – a gas field complex
operated on behalf of the Government of Oman by Petroleum
Development Oman (PDO) - in Oman’s interior. From there, a
gas pipeline approximately 360 kilometres long and 48 inches in
diameter with a gas capacity of 34 million cubic meters a day, is
delivered to OLNG where the gas is liquefied.
CPU card was upgraded
CENTUM VP configuration upgraded
7 Success Story Collection
The Challenges and the Solutions
The LNG production trains 1 and 2 located at the OLNG plant have
been using Yokogawa CENTUM CS production control system
(PCS) since 2000, and train 3 has been controlled by CENTUM
CS since 2005. There have been no major issues in the process
control systems over the course of these years.
With the discontinuation of the UNIX OS system, OLNG decided
to take a phased approach to upgrade its systems from CENTUM
CS to CENTUM VP for all liquefaction trains, a common facility
upgrade involving other systems like Exaopc stations used for PI,
APC (Exasmoc, Exarqe), and metering. Yokogawa’s eLogBook, an
electronic logbook, is now an integral part of the OLNG day-to-
day operations. Operator logging and handover applications are
easily handled by this eLogBook. In addition, the central control
room (CCR) renovation has been completed.
Phase-wise upgrade completion
Oman Liquefied Natural Gas LLC / Oman
Saih Rawl Plant
gas liquid is made up mainly of pentane and hexane that are
Efficient upgrade from CENTUM CS to CENTUM VP removed by fractional distillation of the feed gas after treatment.
Yokogawa Oman office has been offering resident engineer
support to OLNG, since the plant has been operational. This has After the removal of condensates, the gas (mainly methane)
helped to plan the system modifications, upgrades and life cycle
support.
is sent to the main cryogenic heat exchanger (MCHE). The
selected liquefaction process is the propane-pre-cooled mixed
refrigerant (C3-MR) process.
One of the criteria put forth by OLNG was to ensure minimum
downtime for the upgrade work due to tight LNG carriers The liquefaction step is driven by two large turbine-driven
schedules. A phased upgrade approach was adopted for the compressors, which through a series of compression and
three trains and the common utility operation. The human
machine interface (HMI) upgrade was successfully completed
adiabatic and non-adiabatic cooling steps, cools the gas to
minus 162 degrees Celsius, where the gas turns into liquid. The
without any plant shutdown and the main CPU units of field LNG is sent to special storage tanks awaiting shipment by LNG
control station (FCS) were flawlessly upgraded. Various kind of vessels to customers in Asia and Europe.
information related to the HMI such as graphic displays, tag
list, control group displays were migrated from CENTUM CS to
Yokogawa CENTUM VP is fully used as PCS for both plant-wide
operations and specific control strategy and monitoring such as
CENTUM VP using the Yokogawa conversion tool. compressor anti-surge control and start-up/shut-down control.
The upgrade work is completed on schedule. This online Exasmoc multi-variable optimizing controller and Exarqe
upgrade work was a considerable benefit to OLNG with no robust quality estimator packages are applied to maximize the
production loss. liquefaction. The collaboration usage of PCS and APC provides
OLNG a smooth and efficient operation.
Enhanced operator work flow
The operator logging and handover application had issues
and caused issues to maintain and upgrade the application to
Customer Satisfaction
continue to meet OLNG’s latest operating requirements as well Mr. Fahad Al Kaabi, Instrument Engineering Manager of OLNG
as its compatibility with the latest Microsoft operating system. mentioned, “ We are very happy to complete this upgrade. All our
Database corruption was the other issue. OLNG needed a rapid operators reap the benefits of the latest CENTUM VP system and
replacement that could meet the needs of the plant while with the change of the new operating system obsolescence issue
maintaining the company’s high standards. also has been resolved.”
Yokogawa delivered an enhanced release of eLogBook product,
meeting the specific OLNG’s needs. Yokogawa’s eLogBook
is now an integral part of OLNG’s day-to-day operations. The
eLogBook is configured to support specific customer tasks - a
minimum of 15 separate tasks and four instructions.
Each group of OLNG operators can be assigned read / write
access to a specific list of tasks. This enables operators to view,
review and analyze complete activities at any time and at any
location in the plant, which in turn enhances the total operator
workflow.
Double tiered console type HMI (CENTUM CS)
• Shift operation tasks
• Shift instruction tasks
• Shift cycle hand over
• Plant-field (process common facility/storage and loading)
tasks
Optimization of gas liquefaction operation
Acid gas (mainly carbon dioxide), water, and mercury are
removed from the gas delivered to OLNG. This cleaning is a
necessary step to enable liquefaction of the natural gas and
a safe production for OLNG. Condensate which is a natural
Double tiered high density LCD HMI (CENTUM VP)
Success Story Collection 8

LNG Supply Chain
Plant Information
Location: Porto Viro, Italy
Order: 2008
Operation: November 2009
Terminale GNL Adriatico Srl
World’s First Offshore Regasification Terminal Relies
on Yokogawa ICSS (CENTUM CS 3000, ProSafe-RS)
Executive Summary
Terminale GNL Adriatico Srl, commonly known as Adriatic LNG,
was established in 2005 by Qatar  Petroleum, ExxonMobil, and
Edison for the purpose of designing, building, and operating the
world’s first offshore regasification plant. Located in the northern
Adriatic Sea, approximately 15 km off the coast from Porto
Levante, Italy, the Adriatic LNG Terminal (ALT) is a huge state-
of-the-art gravity based structure* (GBS) with facilities for the
mooring and unloading of liquid natural gas (LNG) vessels, two
125,000 m3 LNG storage tanks, and an LNG regasification plant.
Gas from this facility is shipped to the mainland via a newly built
pipeline that connects to the national gas distribution network.
Sitting in waters that are 29 meters deep, the ALT is 375 meters long
and 115 meters wide, with a main deck that rises 18 meters above
sea level and a flare tower that tops out at 87 meters above sea
level. With its nominal 8 billion m3 per year regasification capacity
(equivalent to 775 million cubic feet per day), approximately equal
to 10% of the country’s gas consumption, the ALT is making a
significant contribution to the diversification of Italy’s energy
sources, and is thus contributing to the country’s energy security.
The LNG for this plant comes mainly from Qatar but also from
Egypt, Trinidad & Tobago, Equatorial Guinea and Norway. Edison
has a 25 year contract for 80% of the gas from the ALT, and the
remaining 20% is open to third parties. Of this latter amount, 12%
is allocated according to the procedures defined by the Italian
Ministry of Economic Development and the Regulatory Authority
for Electricity and Gas.
9 Success Story Collection
The Challenges and the Solutions
Acting from the early stages of this project as main instrumentation
and control contractor (MICC), Yokogawa Europe installed an
integrated control and safety system (ICSS). The individual
components of this system are the CENTUM CS 3000 distributed
control system (DCS) and the ProSafe-RS safety instrumented
system (SIS) for IPS/F&G, and it is supplemented by the STARDOM
network-based control system for pipeline monitoring & leak
detection at block valve and metering stations and an operator
training system (OTS) from Omega Simulation.
* A structure that sits on the ocean floor and is held in place by
gravity
Central control room
Terminale GNL Adriatico Srl / Italy
Safe operation Visualization of terminal operations
At the ALT, safety is the top priority. A robust and reliable Systems from other vendors such as the LNG unloading system,
ICSS made up of the CENTUM CS 3000 DCS and the ProSafe- tank gauging system, pipeline monitoring system, metering
RS SIS, together with a leakage detection system powered by system, and gas turbine system are all integrated through a
the STARDOM network-based control system, provide non-stop Modbus interface with the ALT’s main CENTUM control system.
disaster protection. Operation of the ICSS from the CENTUM The resulting ability to visualize process data from throughout
human machine interface is convenient and user friendly. the terminal allows the preparation of production reports,
The SIS and DCS faceplates have the same look & feel, and
security measures are in place that restrict SIS faceplate access
calculation of plant efficiency, and analysis of the performance of
individual processes. Reports on the accumulated running time
to authorized individuals. In an emergency, operators have of rotating equipment such as LNG pumps and compressors are
all the information they need to take immediate and effective compiled, allowing operators to determine the optimum timing
measures including the operation of safety valves. for equipment maintenance and replacement. The visualization
of data from throughout the terminal puts the right data in
Steady supply
Providing a steady supply to the national grid is another
from of the right person, enabling the right decision to be made
at the right time.
important role of the ALT. The terminal has two tanks that can
store up to 250,000 m3 of LNG, an amount sufficient for meeting
four days of demand, so punctual LNG carrier scheduling and
efficient LNG unloading and vaporization are required. The
gas quality is sampled by a GC1000 gas chromatograph and
controlled to meet the specifications of the national grid. Thanks
in good part to the robust reliability of the integrated CENTUM
CS 3000 and ProSafe-RS systems, the terminal has continued
to operate 24 hours a day, 7 days a week, with an availability
approaching 99.5%.
Asset Optimization
The ALT is located offshore, so maintenance of the facilities and
the control system, instrumentation and equipment is essential.
To maintain a stable operation, unexpected field device
failures must be prevented. The ALT uses the Plant Resource
Management package (PRM). Field digital technology allows an
operator to clearly see the status of field devices at any time.
Operators and maintenance crews continuously monitor field
devices from the Control Room using the PRM. Maintenance
activity is scheduled before predicted device failure. Yokogawa
continuously supports the PRM in order to ensure optimized
Weekly demand pattern management of the asset.
Customer Satisfaction
Russell Golson, Operations Manager at the ALT, said, “We are
confident in our ability to provide a steady supply of gas to the
national grid because our integrated control and safety system
is reliable. LNG carrier scheduling, unloading, tank storage, and
vaporizing are all procedure based operations and are carried out
flawlessly. The terminal’s availability is about 99.5%. We strive to
automate terminal operations as much as possible. All process
data is clearly visualized for optimum operation, maintaining a
clear gas business plan and creating optimal LNG supply chain
scenarios.”
Success Story Collection 10

LNG Supply Chain
Plant Information
Location: Bontang,
East Kalimantan, Indonesia
Order date: December 1999
Completion: September 2002
PT Badak
Trains A-D DCS Retrofit & Instrumentation Upgrade
at Natural Gas Liquefaction Plant
Background
PT Badak (a subsidiary of Indonesia’s National Oil & Gas Company,
PERTAMINA) operates one of the largest LNG production complex
in the world, having eight LNG process trains, associated utility
plants and offsite facilities. The first four trains including the utility
plant and offsite facilities (i.e. Module I), were commissioned in
1977 and 1983 respectively. They were being monitored and
controlled by panel mounted single loop controllers. In order to
enhance the reliability and due to obsolescence of equipment of
the Module I plant facilities, an entire revamp / upgrade of the
control, safety and the electrical system took place, with Chiyoda
Corporation being the prime EPC contractor.
The remaining four trains including the associated utilities and
offsite facilities (i.e. Module II) were commissioned in 1989, 1993,
1997 and 1999 and are being monitored and controlled by a
Yokogawa control system, the CENTUM. During the past 15 years
of operation, the CENTUM system proved to operate without a
single shut-down and this high reliability was a key criteria to be
selected for this upgrade project.
Another criteria for the selection of Yokogawa as the control
system supplier for this project was the capability and experience
of cutover work – moving from the existing panel mounted single
loop controllers to the new distributed control system (DCS) with
no interruptions to the LNG production and minimal disturbance
to plant operation. The cutover work consists of both cold cutover
during a maintenance shut-down and hot cutover while the plant
and the control system were under normal operation. In both
cases, expertise that can only be obtained through actual work
experience is mandatory to minimize risks and to achieve smooth
and successful project completion.
Yokogawa’s experiences and capability gained through
successfully conducting such cutover type of projects around the
world, was well recognized by the customer.
11 Success Story Collection
PT Badak / Indonesia
Project Scope & Results
On this project, Yokogawa’s scope was not limited to just the The results and benefits include:
supply of the control system and the cutover work, but also • An increase of steam production from 6%-12% from original
included responsibility for all of the major safety and electrical max load (total of 11 boilers rated 295t/h per boiler)
systems, playing an important role as a system integrator. • Improvement of boiler response time of 6.7 to 7.9 seconds for 1
ton of steam flow rate change
Now, all eight trains including the associated utilities and offsite • A decrease of production down time since the first two trains’
facilities are controlled by the Yokogawa CENTUM, which are
integrated into one system consisting of approximately 100 man-
cutover in September 2001
• Allowed a supervisory computer system that enabled process
machine interfaces and 100 field control stations. As a result data from all eight trains, utilities and offsite facilities of Module
of the change from panel mounted single loop controllers to a I & II to be acquired and monitored at a single location
DCS on Module I, there was an increase in both productivity and
efficiency of plant operations. “We are very proud to have participated in this prestigious project,
and are appreciative of PT Badak, the LNG operators and Chiyoda
- the EPC contractor - for giving us this opportunity and their
strong support throughout this project.”
Project Schedule
Although the project schedule was very tight, the project was
completed ahead of schedule without any trouble. This greatly
owes to the way of working where PT Badak, Chiyoda and
Yokogawa carried out the cutover work as one integrated team.
• The design, engineering and manufacturing were conducted in
a very short time - seven months from kick-off meeting.
• The factory acceptance test including the system integration
test with the sub systems was carefully conducted in four
months.
• It took only 13 months after the kick-off meeting for the start of
the initial cutover work.
• The cold and hot cutover work of 14,810 I/O points was
completed in 13 months with no impact to normal plant Central control room (after)
operation.
System Details System: DCS (CENTUM), Supervisory Computer System, Anti Surge Control,
Vibration & Temperature Monitoring, Hazard Monitoring & Control,
SER (Sequence of event recorder), Field Instruments, Analyzer System,
ESD/EDP Valves, ESD (Emergency Shutdown System)/
EDP (Emergency Depressure System), Electrical Control, UPS, CCTV,
Telecommunication, Public Announcement, Fire Suppression System
Total I/O: 14,810
System Configuration: Man-machine Interface x 47, Field Control Station x 49
(Four LNG Process Trains, Associated Utilities, Offsite)
Scope: System integration and cutover (hot & cold) work
Conventional analog control panel board (before)
Success Story Collection 12

LNG Supply Chain
Plant Information
Location: Nagasaki, Japan
Order date: December 2001
Completion: March 2003
Saibu Gas Co., Ltd.
Compact, Well-designed LNG Terminal Ensures Stable
Supply of Utility Gas
Executive Summary
Saibu Gas Co., Ltd. built an LNG receiving terminal at its Nagasaki
Works to ensure a stable supply of clean-burning utility gas to its
customers in Nagasaki Prefecture. In a project that will serve as a
model for future terminals, Saibu Gas achieved a superb design
that fit all plant functions into a limited area. Yokogawa’s 30 years
of experience in providing control systems for LNG receiving
terminals was instrumental in ensuring a successful outcome for
this project.
- Scalable, flexible configuration with functions distributed to
Nagasaki Works, Saibu Gas
multiple controllers on a facility basis
- Redundant architecture optimally designed for requirements of
entire plant
- General-purpose communications network used for control bus
- Integrated operation environment through web-based human
machine interface (HMI)
“We are very satisfied with the STARDOM system as it has exactly
the kind of ultra-distributed configuration that we had in mind.
The plant started up smoothly, and our operators are comfortable
working with this system.”
13 Success Story Collection
Saibu Gas Co., Ltd. / Japan
The Challenges and the Solutions
Scalable, flexible configuration with functions General-purpose communications network used
distributed to multiple controllers on a facility basis for control bus
The Nagasaki Works employs many cutting-edge technologies Controllers installed over a wide area spanning from the
at its LNG receiving terminal facilities, which include a berth central control room (CCR) to the berth and shipping terminal
for arriving LNG tankers, an LNG regasification plant, and a communicate with each other through Ethernet and fiber-
terminal where LNG is reloaded onto tank lorries for shipping. optic cables. The cost of the new system is reduced by using
STARDOM controllers are assigned to the monitoring and general-purpose network cables and equipment, and reliability
control of the individual facilities, each of which carries out a
different function.
is improved through the use of redundant control buses and
repeaters.
Redundant architecture optimally designed for Integrated operation environment through web-
requirements of entire plant based HMI
Assigning controllers on a facility basis ensures each facility’s A SCADA system with a web-based HMI enables the same
independence, improving the reliability of the entire LNG
terminal. For greater safety, high priority facilities have
operation to be performed at the CCR and the berth control
room, which are 1 km away from each other and are connected
redundant controllers. Facilities with a redundant configuration by fiber-optic cables.
employ a single CPU, eliminating extra investment for higher
cost performance.
Mr. Hayakawa, Manager, Mr. Yamanaka Manager
Nagasaki Works
Total process flow
Mr. Murashima Leader Mr. Masumoto Leader
Nagasaki Works Nagasaki Works
Success Story Collection 14

LNG Supply Chain
Saibu Gas Co., Ltd.
The Site Configuration
Berth control room (FCN autonomous
controller)
Displays are mounted next to the controller
in the berth control room to enable monitor -
ing of the overall site status. A web browser
displays the same information here and at
the CCR, which is 1 km away.
As the HMI information is transmitted via
the control bus, there was no need to install
a separate network.
Berth
In late September 2003, the
Nagasaki Works received its first
shipment aboard the tanker Aman
Hakata, which arrived from Malay -
sia with 18,800 ㎥ of LNG. This
was the ship’s first visit to Japan.
Loading arm
LNG is received through
the on-shore piping, which
is connected through these
loading arms to the tanker
moored at the berth.
15 Success Story Collection
Saibu Gas Co., Ltd. / Japan
About Saibu Gas Co., Ltd.
Founded in 1930, Saibu Gas stably supplies gas to 16 cities and 16 System Details
towns (as of June 2007) in three prefectures of the Kyushu region. Controller: STARDOM FCN Autonomous Controller
Its business operations can be categorized into:
HMI: STARDOM SCADA VDS
- Production, supply, and sales of utility gas
- Heat supply
- LNG sales and cold energy utilization
- Production, sales, and installation of gas appliances, and related
construction work
About the Nagasaki Works
The LNG receiving terminal at the Nagasaki Works was built in
2003 to facilitate the supply of gas to Nagasaki Prefecture. In
Underground LNG tank
this rugged and confined coastal area, Saibu Gas succeeded in
The tank was built underground designing and constructing a berth, regasification plant, shipping
for aesthetic reasons. It has an terminal, and other facilities that enable the stable supply of gas
internal diameter of 37 m and to 120,000 households in the Nagasaki area.
can hold up to 35,000 kl. As LNG
is cooled to -162°C, the inside
of the tank is lined with thermal
insulation and a cold-resistant
stainless membrane.
Gas holder
CCR
All LNG terminal functions including gas
production and storage, maintenance,
and disaster prevention are centrally
controlled from the CCR. The two large
displays give an integrated overview of
operating status, making it possible to
deal with abnormal incidents quickly
and operate the terminal safely.
Success Story Collection 16

LNG Supply Chain
Plant Information
Location: Shanghai, China
Order date: February 2008
Completion: December 2009
Shanghai LNG Company Limited
Yokogawa Provides CENTUM CS 3000 and ProSafe-RS
for China’s Third LNG Terminal
Executive Summary
China is rapidly developing into a major global economic power.
To succeed in its drive to be the center of manufacturing for just
about everything, China has an ever growing need for energy.
One of the big challenges is securing sufficient gas supplies for
the next 25-30 years. Like the country as a whole, Shanghai is
undergoing a transformation into a major global economic center.
In January 2007 it was announced that CNOOC Gas and Power
Limited, a subsidiary of China National Offshore Oil Corporation,
had signed an agreement with Shenergy Group Limited for the
development of the Shanghai LNG terminal by Shanghai LNG
Company Limited (SHLNG). The LNG is transported from Malaysia
to Shanghai, the economic hub of east China. This is the third LNG
terminal in China, with the others being in Guangdong and Fujian.
Its current gas production capacity is 3 million tons per year, and
a second construction phase starting in 2011 will double that.
The Shanghai LNG terminal is comprised of an LNG dock, three
160,500 m3 receiving tanks, regasification facilities, and a 40 km
subsea gas trunk line to Shanghai.
Central control room
17 Success Story Collection
For this project, Yokogawa China successfully installed and
commissioned Yokogawa’s CENTUM CS 3000 distributed control
system (DCS), ProSafe-RS safety instrumented system (SIS),
STARDOM network-based control system, OmegaLand operator
training system (OTS), Exaquantum PIMS, and PRM asset
management system as well as systems from other vendors.
The Challenges and the Solutions
Safety
Safety is an absolute requirement for this LNG terminal. The
ProSafe-RS SIS is fully integrated with the CENTUM CS 3000 DCS,
providing operators a unified operating environment in which
they can monitor all DCS and SIS loops from the same human
machine interface (HMI).
The layout of the central control room is designed with safety
in mind. The mimic panel consoles for the fire and gas system
and the emergency shutdown system follow the same design. A
large screen displays graphics of plant facilities as well as video
from CCTV cameras, so operators can easily spot problems
and take quick action. All systems throughout the terminal are
integrated with the CS 3000 DCS, allowing the Exaquantum
PIMS to gather and process data from nearly 1,500 processes
and display this in 30 different management level screens
that provide information on plant performance, gas demand
scheduling, gas production, gas specification, and nomination
& allocation.
For added safety, Yokogawa installed its OmegaLand OTS. This
simulator is used by both new and veteran operators to acquire
and brush up on essential plant operation skills.
Shanghai LNG Company Limited / China
Steady gas supply
Shanghai relies on this LNG terminal for 40% of its natural gas,
with the remainder coming from the West-East Gas Pipeline and
a coal gasification plant. The CS 3000 DCS is the terminal’s main
control system and its field control stations (FCS) are highly
reliable, with an availability of more than 99.99999% (seven 9s).
The pipeline delivering gas to Shanghai is accurately monitored
and controlled using Yokogawa’s STARDOM network-based
control system and the FAST/TOOLS SCADA monitoring
package. The terminal operates reliably around the clock, 365 Engineering room (DCS/ESD/FGS displays)
days a year.
Maximum automation
A room with engineering workstations is located right next
to the central control room to facilitate the efforts of SHLNG’s
engineers to automate the terminal’s control loops. Currently
more than 90% of the control loops have been automated,
bringing tremendous benefits. SHLNG is now considering certain
procedural changes that will yield additional improvements in
this area, and is using the OmegaLand simulator to optimize
each loop’s control strategy.
Effective use of asset management system (PRM)
Before plant start-up, each loop was checked to make sure that
wiring had been done correctly, signals were being correctly Rack room (CENTUM FCS cabinets)
transmitted, field devices were healthy, and valves were
responding accurately to controller output signals. By helping
to accurately check all these functions, PRM made it possible
to complete the plant start-up ahead of schedule. And by
monitoring the status of all field devices and issuing an alarm
to maintenance engineers when preset conditions are reached,
PRM makes possible a proactive maintenance approach that
significantly reduces total cost of ownership.
Customer Satisfaction
Li Wen, Director of SHLNG’s Facility Equipment Department, said,
“We completed the first phase of this project and are supplying
gas to Shanghai every day without any problems. We supply
nearly 40% of the gas used by Shanghai. It follows that this role
of providing a stable gas supply is a very important one. We ProSafe-RS SIS
very much appreciate Yokogawa’s highly reliable systems and
products. We will continue to improve our operations and will
work to make more effective use of the OmegaLand OTS, PRM,
and Exaquantum. We plan on working with Yokogawa for a long
time to come.”
System Details DCS: CENTUM CS 3000 (I/O: 1,600 points)
ESD: ProSafe-RS (I/O: 700 points)
Pipeline SCADA: STARDOM (I/O: 600 points)
OTS: Exatif & OmegaLand
PIMS: Exaquantum (1,500 points of data on 30 pages)
Asset management system: PRM
Fire & gas system: GE-GMR (I/O: 1,200 points)
Fire & gas detector: CCTV flame, gas detector, beacon, MAC, etc/
Large screen: Planar
Success Story Collection 18

LNG Supply Chain
Plant Information
Location: Stavanger, Norway
Order date: 2009
Completion: 2010
Skangass AS
Yokogawa’s Integrated Solutions Contribute to Safe and
Steady Production at Gas Liquefaction Plant in Norway
Executive Summary
Skangass AS, a joint venture of Lyse AS and Celcius Invest AS,
was established in 2007 with the aim of building and operating
medium-sized low carbon emission energy plants. The company
recently completed construction of a natural gas liquefaction
plant at Risavika in Sola municipality that produces 300,000 tons
of LNG per annum. The plant receives natural gas from a field in
the North Sea via a 50 km high pressure pipeline from Kårstø that
was built by Lyse.
This plant has all the facilities necessary for every phase of the
natural gas liquefaction process, including CO2 removal systems,
a 30,000 m3 storage tank, a coil wound heat exchanger is used as
main cryogenic heat exchanger, a Linde multi-refrigerant cascade
process, and utilities for the generation of electricity and steam. To
ensure safe and efficient operations at this new plant, Yokogawa
Europe successfully installed an integrated plant process control
system consisting of a CENTUM VP distributed control system
(DCS), FAST/TOOLS supervisory control and data acquisition
system (SCADA), ProSafe-RS safety instrumented system (SIS), and
Omegaland operator training simulator (OTS). The plant has been
running smoothly since becoming fully operational in 2010.
Plant process overview
19 Success Story Collection
The Challenges and the Solutions
OTS for familiarization of liquefaction processes
and operator training
Skangass needed to avoid any delays in getting this new plant
fully operational, and key to that was having all plant personnel
fully trained right from the start of operations. For the first
time ever, and in a team effort with Skangass, Yokogawa
configured a full stimulation type operator training simulator
for a gas liquefaction plant, employing the same safety and
automation system (SAS) as the actual plant, with fully identical
operational functions. This high fidelity model of the natural
gas liquefaction process behaves exactly like the actual plant
and allows plant upsets and equipment malfunctions to be
simulated in a stimulative training environment. This makes it
possible for operators at Skangass to undergo repeat training
for a full range of situations.
Skangass AS / Norway
System integration optimizes total plant GC1000 for LNG analysis
operation Yokogawa GC1000 gas chromatographs sample the LNG
Key to maintaining safe operations is for the operators to components and transfer their readings to the CENTUM DCS. With
know in real time what is happening throughout the plant. This this data, operators are able to adjust production specifications to
has been made possible through the complete integration by meet the requirements of the company’s LNG storage terminal
Yokogawa of the plant’s CENTUM VP DCS, FAST/TOOLS SCADA customers throughout Scandinavia.
system, and ProSafe-RS SIS with other systems such as the tank
gauging system. At their control stations, operators can easily
call up and view trend chart, plant overview, alarm summary,
and operation guide graphics, giving them the right information
at the right time on processes throughout the plant.
For example, operators can confirm on screen the status and
operating sequence for the plant’s two drier absorbers, which
alternate on a 24 hour schedule, with one unit operating and
the other regenerating. To guard against thermal shocks during
startup or shutdown, they also are able to monitor temperatures
in the coil-wound heat exchanger, whose operation is key to the
natural gas liquefaction process and which has been carefully
configured in the CENTUM VP system. In real time, operators ROTAMASS for coolant flow measurement
can monitor at their terminals remote terminal data that has A Yokogawa ROTAMASS Coriolis mass flowmeter is used to
been transferred via a general packet radio system link to measure flow in the lines that supply coolant to the plant’s
the Yokogawa FAST/TOOLS SCADA system in the main office,
contributing to the overall efficiency of the Skangass facility and
refrigeration facility. Operators have come to depend on its high
accuracy and stability for determining whether sufficient coolant
ensuring increased safety and stable production. is being provided.
With this integrated system, a single operator per shift can
control the entire plant from the central control room.
.
Customer Satisfaction
Roy Kenneth Skar, Operation Team Leader, said, “Yokogawa
has strong experience in LNG processes, and their engineers
understand our process. The project execution was done by
engineers from Skangass and Yokogawa. The OTS really helped
us to know the process. We are very satisfied with Yokogawa’s
systems for our liquefaction plant. Though our liquefaction rate
is still a small portion of total gas supply from the North Sea gas
field, we are expanding this LNG business continuously to meet
market demand. A constant and steady operation and plant
availability are mandatory to expand our business.”
One operator per shift in the central control room
Mr. Skar
Success Story Collection 20

LNG Supply Chain
Plant Information
Location: Rayong, Thailand
Order: 2010
Completion: 2011
PTT LNG Company Limited
DCS, SIS, PRM, FOUNDATION™ Fieldbus instruments,
and OTS Installed at Thailand’s First LNG Terminal
Executive Summary
Natural gas is Thailand’s primary fuel source and is absolutely
essential to the country’s industries, particularly the power sector:
two third’s of the country’s electricity is generated at gas-fired
power plants. Much of Thailand’s natural gas comes from gas
fields in the Gulf of Thailand. It is transported throughout the
country via a network of offshore and onshore pipelines built by
the national gas and oil company, PTT Public Company Limited
(PTT PCL). In 2005, due to economic growth and the resulting
shortfall in the supply of natural gas, the country’s National
Energy Policy Board resolved to begin importing LNG.
In anticipation of this policy shift, PTT PCL established PTT LNG
Company Limited (PTTLNG) in 2004 and tasked it with building
and operating the country’s first LNG import terminal at Map Ta
Phut, a deepwater port 220 km southeast of Bangkok. They send
out gas to the adjacent Map Ta Phut industrial estate, which is
one of Thailand’s most important industrial areas and home to a
number of petrochemical, oil refining, steel, and fertilizer plants.
PTT LNG terminal overview
21 Success Story Collection
The Challenges and the Solutions
Gas also be transported via the PTT pipeline system to power
companies and other important industrial customers throughout
the country.
Construction of the first terminal commenced in early 2008 and
was completed in 2011, and the terminal began commercial
operation later that year when it received its first shipment of
LNG from Qatar. This terminal includes a jetty capable of receiving
LNG carriers with capacities up to 264,000 m3, two 160,000 m3
full containment LNG tanks, a 5 million ton/year regasification
(vaporizer) train, a boil-off gas recondensor, a sendout station,
and an LNG pump.
To control key terminal facilities, PTTLNG went with a Yokogawa
solution consisting of the CENTUM VP production control system,
ProSafe-RS safety instrumented system, OmegaLand operator
training system (OTS), asset management package - Plant
Resource Manager (PRM), and FOUNDATION™ Fieldbus field digital
technology. Work on this project was executed by Yokogawa, which
functioned as main automation contractor (MAC).
PTT LNG Company Limited / Thailand
Safe, uninterrupted operations
Customers all over the country rely on receiving a regular
supply of gas from this LNG import terminal, which operates
24/7. It is thus absolutely essential to prevent any shutdowns
or other problems that would interrupt this supply. A key asset
that makes this possible is the OmegaLand OTS. In preparation
for the arrival of each LNG carrier, operators in the central
control room (CCR) run simulations of all key terminal processes
such as offloading and regasification on the OTS. This reduces
the likelihood of any mistakes and ensures smooth and safe
terminal operations.
While configuring this fully integrated control system solution
for PTTLNG, Yokogawa strictly followed the following safety
standards:
- NFPA59A (National Fire Protection Association) standard on
production, storage, and handling of LNG
- EN1473 (European Norm) standard on onshore installation
and equipment design for LNG
- SIGTTO (Society of International Gas Tanker and Terminal
Operations Limited) operating standard and best practices
for gas tanker and terminal operations
Once all personnel are all fully trained and gain sufficient
experience in operating this terminal, the plan is for it to operate
with just six personnel on each 12 hour shift: one supervisor,
one board operator, and four field operators.
Asset maximization
The transmitters, flowmeters, and control valves throughout
this terminal are all FOUNDATION™ Fieldbus enabled and can
be continually monitored using the PRM solution. Alarms are
issued before any device fails completely, enabling predictive
maintenance that reduces maintenance costs throughout
the facility lifecycle. The complete integration of all systems
including those at the jetty substation, laboratory, fire station,
LNG import terminal
and truck loading administration room as well as 10 other
subsystems via Modbus communications allows operators at
the CENTUM human interface stations (HIS) in the CCR complete
real-time access to information on operations throughout
the terminal. This ensures that they have all the information
needed to make the right decisions at the right time. PTTLNG is
thus able to make maximum use of all of this terminal’s assets.
Effective operator training
As this LNG import terminal is the first of its type in Thailand, it is
absolutely essential from the safety and efficiency standpoints
for its operators and engineers to always be fully trained on all
system operations and procedures. By using the OmegaLand
OTS for its operation familiarization training programs, PTTLNG
is able to give its personnel repeated training for a full range
of operational procedures as well as all situations that they
can expect to encounter while operating and maintaining this
terminal.
Quality control
Quality control is also essential at this terminal. The results of
gas quality analysis and all associated data are entered into the
laboratory instrument management system (LIMS) server in the
laboratory room and all data are transferred to the CENTUM
system, which generates a laboratory report allowing each
operator to confirm their operating procedures and make any
required adjustments to maintain high quality production.
Truck loading
A portion of the LNG arriving at this terminal is transported in
trucks to local LNG terminals. A terminal automation system
(TAS) keeps track of all essential custody transfer data such as
the truck number, destination, LNG amount, date and time, and
customer name, and this data is all recorded and fed back to the
production control system. So operators can recognize the total
LNG amount versus gasification amount and they can easily
visualize the total efficiency of this plant.
Central control room
Success Story Collection 22

LNG Supply Chain
Plant Information
Location: Hazira, Gujarat, India
Order date: September 2012
Completion: March 2013
Hazira LNG Private Limited
Legacy ProSafe-PLC SIS Replaced with ProSafe-RS to
Improve Sustainable Lifecycle Support at LNG Terminal
Executive Summary
Hazira LNG Private Limited (HLPL), a joint venture between Shell
Gas B.V. and Total Gaz Electricite Holdings, operates an LNG
receiving terminal in Hazira, which is a major port and industrial
hub in India’s Gujarat state. Commissioned in 2005, the terminal
has two 160,000 m3 storage tanks along with re-gasification and
The Challenges and the Solutions
auxiliary facilities that are capable of handling 3.6 million tons of
LNG per year. This is the first LNG terminal in India to be built by
global energy companies.
A 22 km pipeline connects the Hazira terminal to the national gas
grid at Mora Station. The pipeline has sectionalizing valve (SV) and
LNG custody transfer metering (CTM) stations that are located 4
km and 14 km from the terminal, respectively.
The control systems for the Hazira terminal are installed in
its main control room (MCR), which handles all re-gasification
processes and utilities, and at the jetty facility, where arriving LNG
carriers are unloaded.
Original configuration
The Hazira terminal’s process, utility, jetty, and pipeline
operations were all originally automated with a Yokogawa
CENTUM CS 3000 process control system (PCS), a ProSafe-PLC
safety instrumented system (SIS) with emergency shutdown
(ESD) and fire and gas detection (F&G) functionality. The
ProSafe-PLC was connected to the PCS via a MULCOM multiple
protocol communication interface unit, an M-net bus (SIS
control bus), and a V net bus (PCS control bus), with all these
systems sharing the same human machine interface (HMI).
New configuration
As the legacy ProSafe-PLC system was costly to maintain and
was reaching its end of support date, Yokogawa India proposed
that HLPL upgrade to Yokogawa’s latest SIS offering, ProSafe-
RS. After considering the merits of adopting the latest hardware
and software, which included the use of a single control bus for
all terminal facilities, the seamless use of the same HMI for both
23 Success Story Collection
PCS and SIS, and improved safety and integrity, HLPL opted to
go with Yokogawa India’s migration proposal.
Migrating application logic while keeping
existing engineering philosophy
HLPL was specific in its requirement that the ProSafe-RS system
had to retain the same engineering philosophy used with the
ProSafe-PLC system. HLPL also insisted that the migration
project should leverage the latest advances achieved in the
ProSafe-RS system software blocks.
Yokogawa’s PLC2RS tool for converting from ProSafe-PLC
to ProSafe-RS applications proved to be extremely effective
in fulfilling the client’s requirement to retain the essential
engineering features of the terminal’s existing systems. The
base application output by the conversion tool implemented all
the latest features of the ProSafe-RS software. The engineering
output was a perfect blend of the original engineering
philosophy and the latest software features, and engineering
time was drastically reduced.
ProSafe-PLC system cabinet system cabinet
Network migration and integration with existing
components
The key point was the need to replace just the SIS (ESD & F&G)
while keeping the existing PCS and F&G mimic panel as is.
This involved the removal of the MULCOM interface unit and
ProSafe-PLC components and their replacement with ProSafe-
RS components on a Vnet/IP control bus. To enable the use of
the existing PCS network (V net), Yokogawa India installed an
AVR10D V net router.
The most challenging aspect of this migration was the software,
which included special logic on the PCS for controlling the
MULCOM interface unit. To reduce network load, Yokogawa
India conducted a thorough investigation and was able to
remove this logic without impacting the PCS logic.
In addition, the MULCOM interface unit had ISA-F3A alarm
indication logic for the F&G mimic panel.
All of this functionality was successfully embedded in the
ProSafe-RS system, and HLPL continues to use the mimic panel
as an operation interface.
Continued operation of BOG and MSO
compressors during migration
For the project execution phase, HLPL inquired whether it
would be possible for safety reasons to continue operating
two boil off gas (BOG) compressors and a minimum send out
(MSO) compressor. Yokogawa India took up this challenge in
spite of the fact that the running/trip logic for this equipment
resided on the existing ProSafe-PLC system, which needed to
be disconnected as part of the migration. The company offered
an innovative workaround by implementing this logic on a
stand-in ProSafe-RS system that was temporarily hooked up
to the existing PCS for the duration of the migration process.
Following the completion of all migration activities, the data on
the stand-in system was merged with that on the main ProSafe-
RS system.
Exhaustive planning coupled with clinically perfect execution
helped Yokogawa India meet this client’s demanding
requirements with a minimum of disruption to terminal
operations. As a result, both the BOG and MSO compressors
were able to continue operating throughout the migration
process.
HIS HIS (HMI)
F&G
mimic
V net
MULCOM
M-net
CENTUM
(PCS)
ProSafe-PLC
(SIS)
ProSafe-PLC (before)
Hazira LNG Private Limited / India
Maintaining the same hardware footprint
Given the limited amount of space available in the control and
rack room, HLPL stipulated that the ProSafe-RS system must
have the same footprint as the system that it replaced. It was
indeed a challenge to fit the ProSafe-RS terminal boards into
this space without compromising Yokogawa’s high engineering
standards.
Customer Satisfaction
Yet another primary criterion for this migration project was the
need to complete the entire migration during a planned eight
day shutdown. This was not an easy task considering the fact that
Yokogawa India had to migrate the entire SIS at the main control
room and jetty, and hook this up with the original PCS.
Thanks to the integration of the PCS and SIS, HLPL personnel are
now able to use the same HMI for the PCS and SIS to operate the
entire terminal. All the faceplates and other operation displays
have the same design. This helps to eliminate operator errors
and allows HLPL’s engineering team to use the same engineering
environment to make configuration changes to the PCS and SIS,
reducing both engineering workload and maintenance costs.
A key factor in the success of this project was the micro level
planning for the site erection and commissioning activities and
the clear definition of roles and responsibilities for each member
of multilevel teams that worked round the clock.
As a testimony to Yokogawa India’s success in this endeavor, HLPL
offered the following generous praise:
“The Yokogawa team performed the engineering, design, pre-FAT,
and FAT so well that the site installation and commissioning were
flawlessly completed. This was an important aspect in ensuring
that the installation and commissioning were completed by the
targeted completion date. The team’s excellent knowledge and
commitment were also visible in pre-shutdown activities, where
many activities had risks of manual errors that could cause a
process shutdown; however all these activities were completed
impeccably.”
“The project was very challenging as it had to be completed
in eight days and had to be integrated well with other HLPL
shutdown activities. The Yokogawa team’s meticulous planning
and flexibility in making necessary schedule changes helped
a lot in preventing conflicts with other concurrent shutdown
activities. Yokogawa India’s customer focused approach is highly
appreciated.”
HIS HIS (HMI)
F&G
mimic
V net
AVR10D
Vnet/IP
CENTUM
(PCS)
ProSafe-RS
(SIS)
(after)
Success Story Collection 24
 Success Story Collection
LNG Supply Chain

YOKOGAWA ELECTRIC CORPORATION

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